Coil Component With Segmented Magnetic Layer Insulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing coil components lack sufficient insulation between the coil conductor and outer electrodes, which affects their reliability and electrical characteristics.

Innovation Solution

A coil component design that incorporates a magnetic portion with two regions of metal particles of different average sizes, where a region with smaller particles provides high insulation and another region with larger particles enhances magnetic permeability, ensuring effective electrical connectivity and reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If metal particles with uniform size are used in the magnetic layer, then the manufacturing process is simple, but the insulation between coil conductor and outer electrodes is insufficient

Engineering Contradiction:

Improveinsulation between coil conductor and outer electrodesVSAvoidstructure of magnetic layer

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The magnetic layer is divided into two distinct regions: a first region containing metal particles with a first average particle size and a second region containing metal particles with a second average particle size. This local differentiation allows the first region to provide high insulation between the coil conductor and outer electrodes, while the second region optimizes other magnetic properties, thereby resolving the contradiction between insulation reliability and structural simplicity.

Inventive Principle:

Principle #3Local quality

2Reliability

If metal particles with smaller size are used to improve insulation, then insulation between coil conductor and outer electrodes improves, but magnetic permeability decreases

Engineering Contradiction:

Improveinsulation between coil conductor and outer electrodesVSAvoidmagnetic permeability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The magnetic layer is segmented into two regions with different metal particle sizes. The first region with smaller metal particles provides high insulation between the coil conductor and outer electrodes, while the second region with larger metal particles maintains high magnetic permeability. This segmentation allows both insulation reliability and magnetic strength to be optimized simultaneously without compromising either property.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design achieves improved insulation and magnetic permeability, leading to enhanced withstand voltage and inductance while maintaining good electrical characteristics, thus addressing the insulation gap in existing coil components.

Implementation Method 1

a magnetic portion containing metal particles

Methodology Applied

Scientific EffectMagnetic permeability: Ferromagnetism

Implementation Method 2

the region A is present between outer electrodes of the pair of outer electrodes and the coil conductor

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Data Source

PatentUS11600428B2Coil component

Publication Date: 2023.03.07 MURATA MFG CO LTD

AI summary

A coil component includes an element body including a magnetic portion containing metal particles and a coil conductor embedded in the magnetic portion, and at least a pair of outer electrodes disposed on the element body and electrically connected to the coil conductor. The magnetic portion includes a region A containing metal particles having a relatively small average particle size and a region B containing metal particles having a relatively large average particle size. The region A is present between outer electrodes of the pair of outer electrodes and the coil conductor.